Roof Rack Sizing

[Matt]

Well, im fairly certain that my next "big" mod is going to be a roof rack. There have already been a few times that I wish I had a rack up there to strap stuff to.

Looking at rack options and I want something big, for 3 reasons:
1- If im putting something up there, I want to utilize as much space as possible
2- I want something long enough to strap skis and snowboards down to (most of which are under 6' long)
3- I like the looks of a large rack (hehehehehe snicker snicker snicker snort snort). Seriously though, they look weird from the rear if they're too thin, and if they're too short they look like a "top hat".

So I started taking some measurements and really think that, talking in terms of outside dimensions, a 47.5" x 72" rack is the way to go.

The reason I'd like to keep the rack around 47.5" is because the roof rack rails are closer together in the rear of the XK and I want to make sure my rack does not extend over the rails. There are two reasons for this:
1- I am going to make my own load bar mounts. If the roof rack extends over the location where my bolt [or attachment mechanism] is going to be for the load bar mount, then I limit myself to load bar and mounting options. For example i'd have to use a recessed type load bar mount, which would work with Sals unistrut setup, but I'd like the ability to use Thule, Yakima, etc load bars if so desired. And the extra 1" width isn't that big of a deal when im already talking about an inside width of over 45".
2- I want to be able to attach accessories to the side of the rack and have them still confined within the width of the roof. There's a few reasons for this... from aesthetics to trail clearance and even just so you dont have residual rain water dripping on passengers as we enter/exit the vehicle.

I took some width measurements where I think the rear-most crossbar would mount. The leading edge of the tape is on the inside edge of the roof rail, so I still have some space between where these measurements are and where the cross rail mounting bolts would be:

https://theultimatejeep.com/images/imported/2011/07/20110723125015-1.jpg

https://theultimatejeep.com/images/imported/2011/07/20110723124904-1.jpg

https://theultimatejeep.com/images/imported/2011/07/20110723124929-1.jpg

As far as the length is concerned... It looks like 72" is the way to go. I could possibly go further, but I don't want it to look like a visor hanging over the dip in the roof. And, which i'll get to later, im likely going to have Doc fab one up for me so i have to stick within a 20` circumference. So 72" is pretty much the max if im going to be close to 48" wide.

I also wanted to give it some room in the back so that there wouldn't be any interference with the hatch open. In the following pics you can see where the 72" long rack would probably sit...

https://theultimatejeep.com/images/imported/2011/07/20110723124813-1.jpg

https://theultimatejeep.com/images/imported/2011/07/20110723124743-1.jpg

https://theultimatejeep.com/images/imported/2011/07/20110723124802-1.jpg

Thoughts?

UPDATE:

CLICK HERE TO JUMP TO POST #59 (http://www.xk-forum.com/showthread.php/970-Roof-Rack-Sizing?p=13993&viewfull=1#post13993) <------ Start roof rack install here

[Matt]

So now... the roof rack options.

The closest thing that ORU makes to my desired size of 47.5x72 is a 42x72. Granted, that's not bad... it's only 5" thinner than ideal, but they're not exactly cheap racks and there has been some questionable quality issues raised on the forums.

I was checking out Neils bajarack megamule. It's got the width right at 48"... but its 64" long. The length isn't that bad of a thing... but its cutting it close, it would put the leading edge at the top of the crest in the roof (looking back at my pictures, it'd be at the 8" mark in the tap). So that's definitely an option. My concern here is that I may run into issues trying to put my skis on that rack and opening up the rear hatch. The skis would have to protrude out the rear of the rack (which seems doable), so i might have to move the rack forward a bit to compensate. However, there is the chance that the skis will be high enough up that the hatch won't hit them when open.... just some things im thinking about.

Without a doubt i'm going to get a quote from Doc. I actually have a friend with an F150 that may be interested in a roof rack as well... so maybe if we order two we can split the shipping (depending on how Doc ships them... pallet?).

Edit: Oh and Surco has a 45x60. Again, not bad on the width.... i can make that work. But 60 is just going to be too short.

[Matt]

Another roof rack option that I just came across is the Yakima MegaWarrior (#8007080). It's LxWxH dimensions are 52x48x6.5.

At first I thoght "damn, whats with the short racks?" then remembered that Yakima has extension kits. Add on p/n #8007082 which is a 22" extension and I'll be sitting at a solid 74x48x6.5. So other than custom built by our forum local, the Yakima looks pretty good as well. (Price isn't that bad... $315 with free amazon price shipping, plus another $120 for the extension. So around $440 said and done definitely makes it a solid option)

[pjmjr508]

this is what I have & I like it.
http://4xguard.com/Product/RoofRack.html
the size is 66 x 37.5 x 4 inches

[Matt]

Yeah the Rola Racks are nice and price very competitively. They're just way too thin. Don't take this the wrong way, but I think they look kind of strange in the front and rear views... kind of like someone ordered the "wrong size" rack for the vehicle. If they had a 45-48" width option then they'd be in serious contention.

Edit: they do seem to fit the WK's better though...

[pjmjr508]

I do see what your saying, I have my hi-lift jack attached to the side of it. That along with the rack equals out I feel.

[AJeepZJ]

I don't know how many of you get the 4wheelparts magazine issue. I followed this one article in the June 2011 article and it is a SICK roof rack that was custom made by the XXXpedition team. Granted this is on an JK. BUT, i'm sure something similar, or even better, could easily be made for the WK/XK - since we have a stiffer more sturdy frame above. Check THIS (http://www.xxxpedition.com/XXX-Project/index.html) link to see the rack i'm talking - thing is ridiculous.

then click the triangle with the XXX - no it's not sketchy material or anything****

[Matt]

I do see what your saying, I have my hi-lift jack attached to the side of it. That along with the rack equals out I feel.

Ah yeah.. good point. High lift on one side and a shovel or something on the other would even it out quite a bit. The majority of my use will be for sports and/or family trips, so that's another reason id like to optimize the width.


I don't know how many of you get the 4wheelparts magazine issue. I followed this one article in the June 2011 article and it is a SICK roof rack that was custom made by the XXXpedition team. Granted this is on an JK. BUT, i'm sure something similar, or even better, could easily be made for the WK/XK - since we have a stiffer more sturdy frame above. Check THIS (http://www.xxxpedition.com/XXX-Project/index.html) link to see the rack i'm talking - thing is ridiculous.

Doc can pretty much fab up anything we want. That's why my #1 option right now is to have him make me a roof rack to size. I'm fairly certain that his roof racks are more sturdy than our XK's roof is anyways, lol. I'll definitely be using a triple crossbar installation regardless of which rack I go with, but especially with Doc's.

On another note, my friend works at a bike shop... happens to be a Yakima dealer as well. So he's going to get some prices for me. There are some other reasons I like the Yakima, but not really offroad reasons. It comes with accessory crossbars for mounting any of their attachments on to... so i'd be able to throw a fork mounted bike carrier up there (when I ride, im usually meeting people... so its kind of annoying to throw my Thule Revolver in the hitch every time for carrying 1 bike..)

[AJeepZJ]

I used to sport all 3 at one point, but I love Yakima. At one point I had Yakima Crossbars, 2 Yakima Bike racks, It was fine loading and unloading bikes. But then I lifted the dang jeep and tossed the Yakima Load Warrior up there.. It became a PITA to take the bike on and off it. I ended up selling the Bike Racks, and bought a Thule hitch receiver bike rack.

I'd pay some good coin for the Megawarrior

[Matt]

Back when I had my lifted explorer and 2 bike racks on the roof I used to carry around a milk crate to stand on for loading/unloading the bikes https://theultimatejeep.com/notfound.png

Now when I lift the XK some more... that'll be a challenge! But that's not going to happen for at least another year and a half.. .possibly longer depending on how work goes.

I am hoping that the Yakima markup is quite high. If i can get that rack for a really good price, that could potentially mean some rock rails in the very near future... and then i'll be all set for some Rousch Creek wheeling next spring!!

[Matt]

Just figured i'd point out that on ebay the Megawarrior is going for $290 shipped and the extension kit is $110 shipped. Seems like a pretty solid rack for $400.

Some shots i found of the megawarrior + extension:

https://theultimatejeep.com/images/imported/2011/07/DSCF0466-1.jpg

[Matt]

Looky what I came across! I'd be lower down using a different cross rail mounting.. his looks really tall in that first pic for some reason... think it has to do with the angle the pic was taken making it hard to decipher between the side of the rack and the bottom. But size wise is pretty much right on :cool:

https://theultimatejeep.com/images/imported/2011/07/DSC08522-1.jpg

https://theultimatejeep.com/images/imported/2011/07/DSC08518-1.jpg

[AJeepZJ]

Yeah that looks good, I want to get a Megawarrior now... Don't think I'll need the extension.. But it will work great with my already Yakima Crossbars. Really enjoying the pic of that WJ, lol.

[Matt]

Do it man: Here you go $290 (http://cgi.ebay.com/Yakima-MEGAWARRIOR-Vehicle-Roof-Cargo-Rack-NEW-/360379854886?pt=LH_DefaultDomain_0&hash=item53e8503026)

Only thing I dont like about these vehicles is how high the crossrails are... So im just going to make my own mounts. I already have an idea of what im doing for the shape of the mounts, but i'd like to think of a way to make them lockable. I have some time to think about it though.

[AJeepZJ]

Here is the rack I was talking about, it's a little more clear to see the set up.

https://theultimatejeep.com/images/imported/2011/07/photobucket16911311447270748-1.jpg

[Matt]

Ah. That is sweet but its very "purpose built". I want an all around use rack... offroading, skiing, family cargo, camping, picking up toys, etc.

[Sal-XK]

The one thing I will add is if you go to far forward the wind noise and drag will be apparent to you.


Sent from the beach LOL.

[Matt]

Yeah i've been thinking a bit about the wind noise. Keeping it as low pro to the roof will be key. Since I'm probably going to be forward of the roof crest, i'll probably get a sunroof deflector which should help kick the air up and catch the wind deflector of whichever rack I put on.

[Doc in AZ]

I know a good fabricator that makes a lot of jeep stuff, roof racks even. He's also a vendor for transamerican, they own 4wheelpart.

Seriously, you have to email me for price quotes, I came send them thru PM. [email protected]

[Matt]

Ah... didn't know that man. lol I sent you a PM. E-mail will be on it's way :)

[Doc in AZ]

I made just a light rack for Jon's rhinorack a couple days ago.... again, spy quality photos to keep the anticipation high

https://theultimatejeep.com/images/imported/2011/07/470e676aorig-1.jpg

[Matt]

Another reason to move to AZ.... i can take my own spy photos...

[NeilSmith]

When i first installed my BajaRack I had some wind noise. When I installed the lights the wind noise completely went away. I like the rack sitting up off the roof a little bit. It can be easier to get underneath to attach bungees and I have to get under it to tighten and loosen my mounts. just a couple of thoughts. And dont skimp when fabbing your cross bars because there will come a time when you will want to stand up there.

[Matt]

Talked to my buddy from the bike shop today. Even with his discount, it's just not enough to "not" get a good rack. 99.9% sure I'll be rocking a Doc Rack in the near future :cool:

Being kind of excited about it, i was checking out Docs FB page and decided to take a break from messing around with my mounting ideas.... I felt like making an XK sized rack :D

https://theultimatejeep.com/images/imported/2011/07/RoofRack-1.jpg

Doc if you read this, just a quick note.... I've never built my own rack and know you're experienced as hell. I was just messing around with Pro-E tonight. When I get my rack from you, I'm going with your design, not my amateur 45 minute "wannabe roof rack designer" 3D model.

[Doc in AZ]

You put more effort into the design process than I ever did... lol... drew it with Sharpie marker on the steel welding table, did some long hand math right there on the table and started bending. Keep in mind my side tabs are not sheet metal they are 3/16" steel plate waterjet cut for precision and accuracy for the holes in the side to mount tools.

[Matt]

lol, well i do failure analysis and mechanical design for a living... how's that saying go? if you like what you do then you'll never work a day in your life? (Well, in my case you have to add in "except for when program managers piss you off" but thats another story, and the reason I read my daily Dilbert comic).

I actually used 1/2" plate for the model and 1" tube. It was just a visualization thing.... and because Jon Stewart was a bit boring tonight.

[cico7]

MAtt, Doc, quit screwing with the stock rack and rail and modifying it. Start over. Meaning, I was looking at a rack on a Hummer today. It's system is the width of the vehicle
and sits quite low. I think you should start with the rails, then the supports, then rack.

Of course it is easy for me to say that since I have no time or money invested in this. Ok, feel free to bash my idea.

[Matt]

Lol that is a valid idea... but would take a considerable amount of time to develop.... and time is money.

I actually emailed doc an idea last night, and now the I have a rack modeled ill probably model my newest mounting idea tonight. Basically I'm thinking Doc may be able to have 3 of the floor crossbars extend about 4" out of each side. Then I would just machine those mounts that I'm developing to clamp around those 1" diameter bars and completely eliminate the need for load bars. The rack can't get much more low pro than that......

Another benefit of this is that the mounts would also work with Yakima load bars... so they'd be dual purpose. They'd also be easier to machine since I wouldn't have to mill a deep square groove... I'd just blast a 1" hole in the mount and then cut it to make it 2 halves.

[pjmjr508]

Maybe you can make some mounts like that for the Rola Roof Racks from 4x so I can remove the cross bars & just have the rack lower & attached to rails & on top of cross bars.

They should clamp up the same way.

[Matt]

Maybe you can make some mounts like that for the Rola Roof Racks from 4x so I can remove the cross bars & just have the rack lower & attached to rails & on top of cross bars.

They should clamp up the same way.

I don't know what the rola mounts look like. Take some pictures and post them in this thread:
http://www.xk-forum.com/showthread.php/972-Custom-Roof-Cross-Rail-Mounts

[cico7]

Maybe you can make some mounts like that for the Rola Roof Racks from 4x so I can remove the cross bars & just have the rack lower & attached to rails & on top of cross bars.

They should clamp up the same way.


pjmjr,
Here is my Rola rack attached directly to my cross bar....

https://theultimatejeep.com/images/imported/2011/07/20110727_122800_107-1.jpg

https://theultimatejeep.com/images/imported/2011/07/20110727_122812_101-1.jpg

https://theultimatejeep.com/images/imported/2011/07/20110727_122820_382-1.jpg

https://theultimatejeep.com/images/imported/2011/07/20110727_122748_944-1.jpg

https://theultimatejeep.com/images/imported/2011/07/20110727_122805_867-1.jpg

[pjmjr508]

I have it setup the same way, but it to high above the jeep. from what I have seen on how Matt wants to make mounts that go directly to the rails to the rack which will remove the need for cross bars and the cross bar towers as well. In turn will make it sold with the roof rails and lower it to the roof. I hope I making sense

[cico7]

I have it setup the same way, but it to high above the jeep. from what I have seen on how Matt wants to make mounts that go directly to the rails to the rack which will remove the need for cross bars and the cross bar towers as well. In turn will make it sold with the roof rails and lower it to the roof. I hope I making sense
I understand and agree. I would like to see that as well.

[IamJEEP]

Lol, you guys are behind the times......Sal and I allready have that low-pro set up on our Jeeps!!! Cheap too! =P

[Matt]

Eh, I'm going for a setup that someone will say "wow, those are sweet mounts! Who made them?" And can say "custom made by me" as opposed to someone saying "oh that's cool.... but not sure if I'd want to mount my rack like that" :p

[pjmjr508]

Lol, you guys are behind the times......Sal and I allready have that low-pro set up on our Jeeps!!! Cheap too! =P

if your talking about the unistrut, I have been following it. From what I have been reading from Matt & correct me if I am wrong that is designing a small riser that attaches to the rail in the roof & then also right to the roof rack verses having cross bars that the rack attaches to. Would like to get rid of anytype of cross bars and have the roof rack attach directly to the rails in the roof.

[Matt]

if your talking about the unistrut, I have been following it. From what I have been reading from Matt & correct me if I am wrong that is designing a small riser that attaches to the rail in the roof & then also right to the roof rack verses having cross bars that the rack attaches to. Would like to get rid of anytype of cross bars and have the roof rack attach directly to the rails in the roof.

Not quite....
I'm having Doc build me a rack. In doing so I'm seeing if its feasible for him to basically incorporate the cross rails as part of the floor of the rack. They would then be mounted to the stanchions I'm developing in the other thread.

If the cross rails can't be incorporated to the rack, then my stanchions turn into a low profile, more secure and more professional looking cross bar (or unistrut) mount.

[Matt]

Doc did suggest making a direct rail to rack mount however. That has some inherent design issues due to the variable cross rail distance. So the mounts get more complicated (and im hand machining them..... wish i had a CNC) and the material cost also skyrockets. So I haven't put much effort towards that since I already see issues.

Edit: I would like to get some good close up pictures of the ORU mounts though. One of my last ideas is to modify their design for a lower version of their mount.

[pjmjr508]

I will make all other comments for this in the other thread to keep on the right track.

[Sal-XK]

Just FYI we have a mesh floor on our baskets which means we can never get rid of our cross rails with out replacing the floor.

[IamJEEP]

Just FYI we have a mesh floor on our baskets which means we can never get rid of our cross rails with out replacing the floor.

Technically we can but, just for looks. If you put any weight up their, it will surely fail. I wonder how difficult/easy it would be to put solid floors on our racks?

[CmmdrDan]

Technically we can but, just for looks. If you put any weight up their, it will surely fail. I wonder how difficult/easy it would be to put solid floors on our racks?

After my trip next week I gonna make an addition 2 rails. That way the floor has max support.

[Matt]

this is what I have & I like it.
http://4xguard.com/Product/RoofRack.html
the size is 66 x 37.5 x 4 inches

Hey man... random thought popped in my head today (I had a 6 hr drive, alone... tend to do a lot of thinking at times like that). Do you know if you have enough room on either side of the rack to mount a fork-mount bike rack to the crossbars next to your rack?

Also, if you can, throw up some pictures.... i haven't really seen a lot of pics with the Rola on an XK- they're mostly distance shots.

[pjmjr508]

I will go out & see how much room I have on both sides and put that up. I will work on getting pictures up this weekend for both this & also for my garage because I know I have to get them up. I have done a lot of work on the XK and need to share pics of it. If you have FB and you can add me as a friend and you can see the pic's I already have up there already.

[pjmjr508]

have about 6 1/2 " on either side to the roof rails.

[Matt]

Awesome man, thanks!

That's definitely enough room for a fork mount bike carrier up there (mtb is my most active sport... its easier to escape for an hour or two for a ride after the kids go to bed). I'll have to check a few things out when I get home..

[IamJEEP]

Awesome man, thanks!

That's definitely enough room for a fork mount bike carrier up there (mtb is my most active sport... its easier to escape for an hour or two for a ride after the kids go to bed). I'll have to check a few things out when I get home..

Food for thought.........you might get tired of reaching up there to mount/unmount your bike every time you go riding. I thought about the same thing and if you ride like I do, the last thing you want to do is stuggle putting the bike on the roof....

[Matt]

I already have my hitch carrier. Its more of a PITA to install/remove that every time. I had roof mounted racks on my lifted explorer, it wasn't a big deal. I kept my bike gear in a crate in the back and used the crate as a stool to remove/install the bike. :)

[Matt]

... nothing will beat the setup I have on my GMC though! Thule sidearms mounted above the bed. Bikes mounted/unmounted shoulder height in 10 seconds.

[IamJEEP]

... nothing will beat the setup I have on my GMC though! Thule sidearms mounted above the bed. Bikes mounted/unmounted shoulder height in 10 seconds.

Perfect highth(sp?) set-up right there. My buddy had that same thing in hid Ranger back in the day.

[cico7]

Perfect highth(sp?) set-up right there. My buddy had that same thing in hid Ranger back in the day.

*Height Does the (sp?) mean correct me if I am wrong or simply not sure of the spelling? This keeps me awake at night. I am never sure what to expect.

[cico7]

... nothing will beat the setup I have on my GMC though! Thule sidearms mounted above the bed. Bikes mounted/unmounted shoulder height in 10 seconds.
Without pics, it doesnt exist....

[IamJEEP]

*Height Does the (sp?) mean correct me if I am wrong or simply not sure of the spelling? This keeps me awake at night. I am never sure what to expect.

Yes Don, it means i am unsure of the spelling. Ever since i started this texting crap, my spelling and grammer have gone to the birds. Lol......

[IamJEEP]

Without pics, it doesnt exist....

This should be in the XK-Forum manual for all to read, LOL...

[Matt]

https://theultimatejeep.com/images/imported/2011/08/Engishtown9252010005-1.jpg

https://theultimatejeep.com/images/imported/2011/08/MudFlaps010-1.jpg

https://theultimatejeep.com/images/imported/2011/08/Sept7001-1.jpg

I really miss that truck. We had a sweet vehicle lineup with the XK and the Sierra.

[cico7]

Can you shift the camera a little to the right, can't see the whole truck....

[Matt]

LMAO
https://theultimatejeep.com/notfound.png

[Sal-XK]

Can you shift the camera a little to the right, can't see the whole truck....

Oh my LMAO

[Matt]

Well.... LONG explanation short, last weekend when I heard 4XG was closing their doors I had to make a drastic decision. The materials for my custom mounts was a bit more than expected, and then I decided to throw in my order for the 4XG bellyguard (which i planned on getting next spring before starting some wheeling trips), so that was another $230ish out of my budget. So, being set back a bit more than expected, the custom rack was just getting further from reach. Add to that there was a deal at etrailers... $250 shipped for the Rola + 18" extension... I couldn't pass it up. Fast shipping too... Ordered Monday and it came in yesterday!!

Oh yea, and since i'm doing 3 crossbars I ordered 2 extra rack mounts (they're $10 each).

Hopefully I'll have this bad boy on tomorrow if I get the cross rail mounts done!

https://theultimatejeep.com/images/imported/2011/08/20110811175257-1.jpg

https://theultimatejeep.com/images/imported/2011/08/20110811190533-1.jpg

https://theultimatejeep.com/images/imported/2011/08/20110811190519-1.jpg

[Sal-XK]

good deal can't wait to see it mounted up.

[pjmjr508]

neither can I because this is the rack I have & might need some of your mounts asa well (if you want to make more).

[Matt]

this is what I have & I like it.
http://4xguard.com/Product/RoofRack.html
the size is 66 x 37.5 x 4 inches

Hey man... did you ever measure the outer dimensions of your rack? I did today https://theultimatejeep.com/notfound.png

It's actually 74 x 41 x 5.... that's right... seventy----freaking-----four. lol holy crap the thing is almost a foot longer than i expected!! I was taking measurements trying to size up where my cross bars would go and it just wasn't adding up, so then I checked!

https://theultimatejeep.com/images/imported/2011/08/20110817202252-1.jpg

https://theultimatejeep.com/images/imported/2011/08/20110817202317-1.jpg

[pjmjr508]

No I never measured the outer, just the interior so I knew how much room I had to work with. I still think it sits nicly up there just need to bring it lower to the roof. Also I don't know how you have your hi-lift jack set up yet, but with this rack I did this.
https://theultimatejeep.com/images/imported/2011/08/DSC_0107-1.jpg
Hi-lift makes all of it.

[Matt]

Oh yea, it sits up there great. I meant 74x41 as a good thing :)

[Matt]

Installed!!! https://theultimatejeep.com/notfound.png

https://theultimatejeep.com/images/imported/2011/08/20110818190745-1.jpg

https://theultimatejeep.com/images/imported/2011/08/20110818190855-1.jpg

https://theultimatejeep.com/images/imported/2011/08/20110818191815-1.jpg

[pjmjr508]

Looks great

[IamJEEP]

Looks great Matt! Nice and low pro......